Composite building unit



Allg 22, 1939- w. E. s. STRONG COMPOSITE BUILDING UNIT Filed' oct. 24, 1935 Vl BRATOR Fiq' INVEN-roR Wn iam 555i m5 Hl M ORNEY 4 Patented UNITED .STATES PATENT oem-CE william E. s. strong, New van, N. y., miglior u John- B. Pierce Foundation, New York, N. Y.,

r a corporation of New York 1 g f Application ocmber'u, 1935, serial No. 46,454

' 9 cmmgwi 'gz-ser My linvention relates to improved structural units of conci ete or of Acementitious materials 'oi' the nature of concrete.

'Ihe invention relates particularly to structural 4units of a composite nature embodying concrete,

or other cementitious material of the nature of concrete, for structural strength,4 and embodying insulating material for imparting desired insulat-v ing characteristics.

A primary object of the invention is the provision of a concrete structural unit having,. per se, insulating characteristics to a high degree.

An object is the provision of a concrete structural unit of unusually light weight yet having considerable structural strength.

An object is the provision for attaining a molded concrete element having density and strength greater than ordinary tamped concrete.

Pursuant to my invention, a concrete element having improved characteristicsis had by subiecting a masso! plastic concrete to vibration, andl simultaneously therewith to compression. Such treatment imparts desirable properties to the resulting element, and produces a finish on all faces of the element as well as a greater faithfulnessv oi' transfer of the conilgurations of the mold faces. 'The resulting concrete element is highly resistant to water and moisture, and possesses compressive strength, resistance against ruptureby bending, and resistance against peru1 meation by wind, such properties being highly advantageous in the use as a component element of a structural unit.

The concrete element, as a component of the composite structural unit of the invention, is recessed, forming a shell for the reception oi a mass of material of less weight and advantageously of heat and sound insulating qualities. The stated mass of material may be oi' porous character, such as a light weight product Aresulting from a suitable mixturewith water. of ground silica, and/or other siliceous material, and lime, and/or other calcareous elements, usually indurated by heat treatment; or it may be individual elements, such as particles orbers bonded together to form a solid element for fitting into the recess of the concrete shell; or it may be composed of individual elements such as small particles or fibers loosely associated. In the latter case, a cover plate or other suitable element or means may be employed to retain the loose insulating material in place withlnf the reor other structure of a building for exposure to and resistance against all kinds oi weather conditions. A

'I'he uniting of concrete and insulating elements may be carried out in any desirable manner, preierably by a bonding medium of water resistant character interposed between the two elements. Further features and objects of the invention will be more fully understood from the following detail` description and the accompli-Dying draw-v i'ng, in which Fig. 1 is'a perspective view oi' a preferred form of buildingV unit embodying an outer element of vibrated and compressed concrete and s therewith unitarily combined inner element oi lesser density. Fig. 2 lisa vertical sectional view of amold charged with a cementitious mixture sublected to vibration under pressure. v

Fig. 3 is a top plan view of Fig. 2. Fig..4 is a vertical section of the compressed cemntitious structural element resulting fmm the steps of Figs. 2 and 3, a portion o! the inner bonding medium applied thereto.

Fig. 5 is a transverse sectional view of an ele ment of vibrated andcompressed cementitious mixture, and a charge o1' mixture oi' lesser density disposed in a hollow cavity ot the cementltious element. A

Fig. 6 is a transverse sectional view of the product resulting irom the step indicated in Figl.

Fig. 7 is s transverse sectional view of another embodiment of my invention.

Referring to that preferred form of my product which is illustrated inA Figs; 1 and 6, the element or shell It ci concrete or other cementitious material is illustrated as an outer element and the material il, of lesser density, as an inner" element, the elements I0 and Il, being unltarily assembled as a building block, slab, or other structural unit. 'I'he "outer" element I I of concrete or other cementitious material is preferably the product resulting from subjecting a quantity oi' concrete or the like. to combined pressure and vibration surface of said element additionally a .within the connes oi' a mold to impart the deerection of an outer, inner and/or intermediate wall, partition, floor, roof, or the like.` l

, Such inner material Il may possess such in addition to that of losser asniaybe desired. ndvanteseouslasuoh auch as a component of intermediate walk. y

possess per se the property of adhering to acle adherence orthe like. In such instances wherechemical and/or tentacle` adherence .does not arise, or is sought to be enhanced, a suitable bonding medium I2. may be interposed. v In Figs;V 2 and 3, I have indicated the step of subjecting a mass of concrete or other cementitious admixture Ia to vibration and compression. f 'I3 represents any suitable form and type of mold,

suitably contoured at'its effectillgfaces corresponding to the desired-contours tpfftlle resulting cementitious outer element I0. Advantageously, the bottoni` mold element I3a, which may be of cast metal, is provided with minute 4openings I3b for the discharge of air ensuing during the stage of subjection to vibration, indicated lby the vibrator I4, and to compression indicated by the weight I5, Provision for the discharge of excess moisture is had by the clearance, see I6, Figs. 2 and 3,-

between the lateral faces of the weight I5 and the inner lateral faces of the mold and/or by suitable openings, see I1, Fig. 2, in the mold. The mold I3 is preferably of disassembling character, that is to say, the side frame I3c, as a whole or by Vcomponent parts, is separable from the bottomA IBa. The weight I5 is suitably dimensioned and is of suitable mass to produce momentum during the stage of vibration, for effecting a desired degree of density of the resulting product, i. e., the outer the weight I5, is suitably dimensioned and contoured to effect finish and the desired dimension and contour of the recessed faces of the resulting product. r l

The recess of the resulting product is preferably downwardly'and inwardly tapered to provide for adequate strength of the sidewalls of the unit. at their intersection with the bottom wall thereof;

Upon completion of the outer element I0, see Fig. 4, the same is treated for the completion of the desired structural unit| as above indicated. Assuming the employment of a bonding medium I2, the faces,

the outerele1nent I Il are coated with such bonding medium I2,whereafter, an admixture, IIa, see Fig. 5, of the inner material is charged into such recess or recesses. After leveling to remove the excess of such admixture IIa, see Fig. 6, and upon maturing of the inner element II, also that of the bonding medium I2, if employed, there v results the building or other unit of the type indicated in Figs. 1 and 6.

Other form and types of structural units of unitary assembly comprising outer and inner elements as aforesaid may be produced in a similar manner.

As va. suitable cementitious mixture in carrying out my invention, I cite Portland, hydraulic or other cement.

As a type of locculent material, I cite vermiculitel which is rendered iiocculent by heat treatmentand adapted to form a mass of lesser unit weight by bonding with a vsuitablebonding medium such as' Portland, hydraulic or other cement. y

-By reason of the ponent of such outer and inner common cementitious comelements, the

invention, the

is enective upon element I0. The eiective'face Ilia of v in whole or in part of the recessot armies without vibration and/or comprension.

` Pursuant tothe above stated principleeof effect ot ous productie the desired exteiitand accurately and uniformly nersses, inclusive of any horizontal and/or verticattainment of lanyl desired dimensional thicknesses and contours. In such action there the plastic mass the combinational stresses afforded by the weight and the vibration momentum of the mass of the weight.

Deslrably, asis indicated in the drawing the compressing weight, such as the illustrated weight I5, is provided' with' suitable means for limiting its downward movement andamplitude of its momentum oscillations, such means being indicated bythe arms ISU, arranged to finally rest upon the upper face ofthe lateral mold walls Ila or other suitable stop.y l

It will be understood that the total mass and `final wall thicknesses and 'coniigurationgof the unit are selected, with the proper factor of safety, to afford the desired load bearing lattributes and desired density to preclude or retard permeation of water, moisture andthe like; also to preclude or retard permeation of air induced by wind and `other pressure.l Further,v the dimensions and congurations of the combined outer and inner elements may be selected-in correspondence to the desired dimensions-of the wall or 'other structural part of which my combined building unit is adopted to form a component. The character of the bonding material is selected with reference to the above stated characteristics of the combined vibrated and compressed cementitious element and also those of the lesser weight element, to attain the desired combinational characteristics of the stated constituents. Tar.' asphalt, or like water and moisture-resistant materials serve advantageously -as the bonding medium by reason of their low cost and their capu ultaneous/xubieotion to vibra- Y ,tion and compression affords the combinationnly l expelling excess water and other moisture content, .densifying the cementltiattaining the 'desiredy .wall thiksiiA abilityof being readily sprayed in all directions its recess faces IIic, and preferably molded also, as

at IIld, to produce a .counter-recess for receiving a slab or cover p te I8, which slab may be of bonded insulating 4material, similar to that of the of the outer" element I0 above stated material serving as the inner element, i. e.,"inner element I5. Between the slab I8 and the faces of the recess of the outer element III is a quantity of flocculent material of low heat conductivity, and preferably of low sound conductivity such' as heat expanded vermiculite, cork particles, glass wool, etc., the slab I8 being secured to the outer element I0 in any suitable manner, as by asphalt, tar or the like, or by any suitable mechanical means, indicated. at I9.

Embodiments of my invention of the outer element have been obtained under commercial inner element II, or of concrete similar to that 

